Gallium-containing light-emitting semiconductor device and method of fabrication

ABSTRACT

An LED comprising a light-generating semiconductor region having an active layer sandwiched between two confining layers of opposite conductivity types. A cathode is arranged centrally on one of the opposite major surfaces of the semiconductor region from which is emitted the light. An array of discrete gold regions are formed via transition metal regions on the other major surface of the semiconductor region at which is exposed one of the confining layers which is of n-type AlGaInP semiconductor material. The gold is thermally diffused into the confining layer via the transition metal regions at a temperature less than the eutectic point of gold and gallium, thereby creating an array of ohmic contact regions of alloyed or intermingled gold and gallium, which are less absorptive of light than their conventional counterparts, to a thickness of 20 to 1000 angstroms. After removing the transition metal regions and gold regions from the surface of the light-generating semiconductor region, a reflective layer of aluminum is formed so as to cover both the ohmic contact regions and the exposed surface portions of the AlGaInP confining layer. An electroconductive base-plate of doped silicon is then bonded to the reflective layer.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation of Application PCT/JP2003/014890, filed Nov. 21,2003, which claims priority to Japanese Patent Application No.2002-348416 filed Nov. 29, 2002.

BACKGROUND OF THE INVENTION

This invention relates to a light-emitting semiconductor device, orlight-emitting diode (LED) according to more common parlance, and moreparticularly to such devices employing gallium-containing compoundsemiconductors. The invention also concerns a method of making suchlight-emitting semiconductor devices.

The LED has been known which has a light-generating semiconductor regiongrown on a substrate of electrically conducting material such as galliumarsenide. Typically, the light-generating semiconductor region has anactive layer sandwiched between an n-type cladding or lower confininglayer, which overlies the substrate, and a p-type cladding or upperconfining layer. An anode is mounted centrally atop the upper confininglayer whereas a cathode underlies the substrate. The light generated atthe active layer partly traverses directly through the upper confininglayer and issues from that part of the surface of the semiconductorregion which is left uncovered by the anode. The rest of the light isradiated toward the substrate via the lower confining layer. How toreflect this light most effectively back toward the light-emittingsurface of the semiconductor region is of critical importance for thehighest possible efficiency of the LED.

One conventional solution to this problem is a reflective film known asthe Bragg reflector interposed between the substrate and thelight-generating semiconductor region. The Bragg reflector is easy tofabricate by epitaxial growth, the method adopted for subsequentformation of the semiconductor region. Offsetting this advantage is thelack of sufficient reflectivity with respect to the light having a widespectrum of wavelengths.

Another prior art method calls for the removal of the gallium arsenidesubstrate following the epitaxial growth of the semiconductor regionthereon. A transparent baseplate is then bonded to the semiconductorregion in place of the substrate that has been removed, by way of amechanical support for the LED. Then a reflective electrode is attachedto the transparent baseplate. The reflective electrode serves not onlyas electrode but to reflect the light back through the transparentbaseplate toward the light-emitting surface of the semiconductor region.This known remedy is objectionable for a relatively high forward voltagerequired between anode and cathode as a result of additional resistanceat the interface between light-generating semiconductor region andtransparent baseplate.

Japanese Unexamined Patent Publication No. 2002-217450, filed by theassignee of the instant application, represents an improvement over themore conventional devices listed above. It teaches the creation ofisolated ohmic contact regions of gold-germanium-gallium alloy on theunderside of the light-generating semiconductor region. These ohmiccontact regions, as well as the surface of the semiconductor region leftuncovered thereby, are covered by a reflective layer of aluminum orother metal. An electroconductive baseplate is bonded to the undersideof the reflective layer. Making good ohmic contact with thelight-generating semiconductor region of, say, aluminum gallium indiumphosphide, the ohmic contact regions of gold-germanium-gallium alloyserve for reduction of the forward voltage of the LED.

The last cited prior art LED proved to possess its own weaknesses,however. The gold-germanium-gallium ohmic contact regions were ratherinconveniently absorptive of light by reasons of their germanium contentand thickness in particular. The total reflectivity of the ohmic contactregions and reflective layer was therefore as low as 30 percent orthereabouts, making it difficult for the LED to gain sufficiently highefficiency. Another shortcoming concerned the morphology of thegold-germanium-gallium ohmic contact regions: Their surfaces were souneven that difficulties were experienced in bonding theelectroconductive baseplate thereto via the reflective layer.

SUMMARY OF THE INVENTION

The present invention has it as an object to further enhance theefficiency of the light-emitting semiconductor device of the kindincorporating the gold-germanium-gallium ohmic contact regions, or, fora given intensity of light produced, to make the forward voltage of thedevice lower than hitherto.

Briefly stated in one aspect thereof, the invention concerns alight-emitting semiconductor device of improved efficiency comprising alight-generating semiconductor region having a first major surface fromwhich light is emitted and a second major surface which is opposite tothe first major surface. The light-generating semiconductor region isconstituted of a plurality of compound semiconductor layers inlamination including a gallium-containing compound semiconductor layerwhich is exposed at the second major surface of the semiconductorregion. The invention particularly features an ohmic contact region heldin ohmic contact with at least part of the second major surface of thelight-generating semiconductor region. The ohmic contact region is madefrom a mixture of at least two metals including gallium and is perviousto the light generated by the light-generating semiconductor region.Also included is a reflective layer of electrically conducting materialheld against at least either of the ohmic contact region and that part,if any, of the gallium-containing compound semiconductor layer of thelight-generating semiconductor region which is exposed at the secondmajor surface of the semiconductor region through the ohmic contactregion, for reflecting the light from the semiconductor region backtoward the semiconductor region for emission from the first majorsurface thereof.

Preferably, the gallium-containing compound semiconductor layer of thelight-generating semiconductor region is made from one of the followingthree compound semiconductors and a conductivity-type determinant:

-   -   (a) a first compound semiconductor that is generally expressed        as Al_(x)Ga_(y)In_(1-x-y)P where the subscript x is a numeral        that is equal to or greater than zero and less than one; the        subscript y is a numeral that is greater than zero and equal to        or less than one; and the sum of x and y is greater than zero        and equal to or less than one;    -   (b) a second compound semiconductor that is generally expressed        as Al_(x)Ga_(y)In_(1-x-y)As where the subscript x is a numeral        that is equal to or greater than zero and less than one; the        subscript y is a numeral that is greater than zero and equal to        or less than one; and the sum of x and y is greater than zero        and equal to or less than one; and    -   (c) a third compound semiconductor that is generally expressed        as Al_(x)Ga_(y)In_(1-x-y)N where the subscript x is a numeral        that is equal to or greater than zero and less than one; the        subscript y is a numeral that is greater than zero and equal to        or less than one;

and the sum of x and y is greater than zero and equal to or less thanone.

Preferably, the ohmic contact region is made, by the method of thisinvention to be summarized subsequently, from a mixture or alloy ofgallium and gold to a thickness of from about 20 to about 1000angstroms. Further the ohmic contact region is divided into an array ofdiscrete regions, which are embedded in the second major surface of thelight-generating semiconductor region. Thus the discrete ohmic contactregions substantially “cover” parts of the second major surface of thelight-generating semiconductor region and leave the rest of the surfaceexposed. The reflective layer is held against both the ohmic contactregions and the exposed part of the second major surface of thelight-generating semiconductor region. The reflective layer may be madefrom aluminum or like metal for higher reflectivity than the ohmiccontact regions.

Made from a mixture or alloy of gallium and gold in particular, theohmic contact regions according to the invention are far less absorptiveof light than the prior art gold-germanium-gallium ohmic contactregions. The less absorptive ohmic contact regions permit, of course, acorrespondingly higher percentage of the light from the light-generatingsemiconductor region to pass therethrough for reflection by thereflective layer back toward the light-emitting first major surface ofthe semiconductor region. Thus, for a given voltage applied, the devicewill emit light of greater intensity than heretofore.

Conversely, for a given output light intensity, the ohmic contact regionor regions may be greater in surface area with respect to the area ofthe second major surface of the semiconductor region, to an extentcorresponding to the increased amount of light reflected back throughthe ohmic contact regions. That is to say that the same output lightintensity is obtainable if the ohmic contact region or regions are madegreater than hitherto. Such larger ohmic contact region or regions leadto less resistance to current flow through the device, to less forwardvoltage, to less power loss, and hence to higher efficiency of lightproduction.

It is also recommended that the ohmic contact region or regions be madeas aforesaid from about 20 to about 1000 angstroms in thickness. Made sothin, the ohmic contact region or regions will absorb even less lightand permit an even higher proportion of the incoming light to bereflected back toward the light-emitting surface of the device.

Another aspect of the invention pertains to a method of making thelight-emitting semiconductor device of the above summarizedconstruction, with a particular emphasis on how to create the ohmiccontact region or regions. There is first prepared the light-generatingsemiconductor region including the gallium-containing compoundsemiconductor layer which is exposed at the second major surface of thesemiconductor region. By way of preparation for creation of the ohmiccontact region or regions in this second major surface of thesemiconductor region, a transition metal layer is formed on at leastpart or parts of the second major surface. Then, on this transitionmetal layer, a diffusible metal layer is formed which contains a metal,preferably gold, that can be thermally diffused into thegallium-containing compound semiconductor layer of the light-generatingsemiconductor region through the transition metal layer. The desiredohmic contact region or regions are created in the gallium-containingcompound semiconductor layer of the light-generating semiconductorregion by the thermal diffusion of gold or the like as the article issubsequently heated to a temperature less than the eutectic point of themetals concerned, which are gallium and gold in the illustratedembodiments. Then the transition metal layer and diffusible metal layerare both removed from the light-generating semiconductor region. Thenthe reflective layer is created on at least either of the ohmic contactregion or regions and that part, if any, of the gallium-containingcompound semiconductor layer of the light-generating semiconductorregion which is exposed at the second major surface of the semiconductorregion through the ohmic contact region or regions.

Particular attention may be paid to the transition metal layer throughwhich gold is diffused into the gallium-containing compoundsemiconductor layer of the light-generating semiconductor region. Thetransition metal is capable both of solid-phase decomposition of thecompound semiconductor into the individual elements and of cleansing thesemiconductor surface. These inherent capabilities of the transitionmetal enable solid-phase gold diffusion into the gallium-containingcompound semiconductor layer at a temperature as low as below theeutectic point of gallium and gold. Formed in this manner bylow-temperature solid-phase diffusion, the ohmic contact region orregions are of minimal thickness and are highly favorable in surfacemorphology, besides being free from germanium or other metal thatinterferes with the passage of light therethrough.

The above and other objects, features and advantages of this inventionwill become more apparent, and the invention itself will best beunderstood, from a study of the following description and appendedclaims, with reference had to the attached drawings showing thepreferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross section through an LED embodying the principles ofthis invention.

FIG. 2 is a transverse section through the LED, taken along the lineII-II in FIG. 1.

FIG. 3 is a cross section through the light-generating semiconductorregion of the LED, shown by way of a first step for fabricating the LEDof FIG. 1 by the method of this invention.

FIG. 4 is a view similar to FIG. 3 but additionally showing a transitionmetal layer and diffusible metal layer formed in discrete regions on thelight-generating semiconductor region.

FIG. 5 is a view similar to FIG. 4 but additionally showing the ohmiccontact regions formed in the light-generating semiconductor region bythermal diffusion of the diffusible metal through the transition metallayer.

FIG. 6 is a view similar to FIG. 5 except that the transition metallayer and diffusible metal layer of FIGS. 4 and 5 are not shown becausethey have been removed upon creation of the ohmic contact regions as inFIG. 5.

FIG. 7 is a view similar to FIG. 6 but additionally showing thereflective layer subsequently formed on the FIG. 6 article.

FIG. 8 is a view similar to FIG. 7 but additionally showing theelectroconductive silicon baseplate bonded to the FIG. 7 article.

FIG. 9 is a graph plotting the relationship between the reflectivity ofthe LED according to the invention in comparison with that according tothe prior art.

FIG. 10 is a view similar to FIG. 1 but showing an alternate form of LEDaccording to the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is believed to be best embodied in the LED showncompleted in FIGS. 1 and 2 and in successive states of fabrication inFIGS. 3-8. Generally designated 1 in FIG. 1, the representative LEDbroadly comprises:

-   -   1. A light-generating semiconductor region 2 where light is        produced and which is constituted of several layers in        lamination to be set forth shortly.    -   2. An anode 3 of open-worked or meshed design on a first 15 of        the pair of opposite major surfaces of the semiconductor region        2, the first major surface 15 being hereinafter referred to as        the top surface of the semiconductor region.    -   3. An array of isolated ohmic contact regions 4, to which the        present invention is specifically directed, on the other major        surface 16, hereinafter referred to as the bottom surface, of        the semiconductor region 2.    -   4. A reflective layer 5 covering the whole array of ohmic        contact regions 4 as well as that part of the bottom surface of        the semiconductor region 2 which is left exposed through the        ohmic contact regions.    -   5. An electroconductive silicon baseplate 8 joined to the        underside of the reflective layer 5 via bonding metal layers 6        and 7.    -   6. A cathode 9 underlying the electroconductive silicon        baseplate 8.    -   7. A current blocking layer 10 formed centrally on the top        surface of the semiconductor region 2 in underlying relationship        to part of the anode 3.

The light-generating semiconductor region 2 as the semiconductor body isshown as a lamination of an n-type semiconductor lower confining layeror cladding 11, an active layer 12, a p-type semiconductor upperconfining layer or cladding 13, and a current spreading layer 14 of ap-type compound semiconductor, all grown by epitaxy in that order on asubstrate, not shown, of any known or suitable composition. Thesubstrate for growing the layers 11-14 of the light-generatingsemiconductor region 2 is not shown because it is removed following thefabrication of all these layers and is absent from the completed LED 1.The current spreading layer 14 provides the above defined top surface 15of the semiconductor region 2 whereas the n-type lower cladding 11provides the bottom surface 16 of the semiconductor region. Generated inthe active layer 12, the light traverses the upper cladding 13 andcurrent spreading layer 14 and issues from the top surface 15 of thesemiconductor region 2.

The n-type lower cladding 11 of the light-generating semiconductorregion 2 is made from, in addition to an n-type dopant such as silicon,any of gallium-containing III-V compound semiconductors that aregenerally defined as:Al_(x)Ga_(y)In_(1-x-y)Pwhere the subscript x is a numeral that is equal to or greater than zeroand less than one; the subscript y is a numeral that is greater thanzero and equal to or less than one; and the sum of x and y is greaterthan zero and equal to or less than one. Preferably, the aluminumproportion x is from about 0.15 to about 0.45, and most desirably fromabout 0.2 to about 0.4. The gallium proportion y is preferably fromabout 0.15 to about 0.35, and most desirably from about 0.4 to about0.6. The n-type impurity may be added to this lower cladding 11 to theconcentration of 5×10¹⁷ cm⁻³ or more. The gallium content of this lowercladding 11 is conducive to the formation of the ohmic contact regions 4of alloyed or intermingled gallium and gold, as will be later explainedin more detail. As is well known, the lower cladding 11 has a greaterbandgap than does the active layer 12.

As required or desired, an n-type contact layer of Groups III-V compoundsemiconductor material might be formed under the n-type lower cladding.The semiconductor materials for this n-type contact layer can also beexpressed as Al_(x)Ga_(y)In_(1-x-y)P.

The active layer 12 of the light-generating semiconductor region 2 ismade from any of p-type Group III-V compound semiconductors that aregenerally defined as:Al_(x)Gu_(y)In_(1-x-y)Pwhere the subscripts x and y are both numerals that are equal to orgreater than zero and equal to or less than one, and the sum of x and yis equal to or greater than zero and equal to or less than one.Preferably, the aluminum proportion x is not less than about 0.1.

No conductivity determinant is added to the active layer 12 in thisembodiment of the invention. In practice, however, the active layer 12may be doped with a p-type determinant to a concentration less than thatof the p-type upper cladding 13, or with an n-type determinant to aconcentration less than that of the n-type lower cladding 11. Theshowing of the single active layer 12 in FIG. 1 is for the sake ofsimplicity only; in practice, it may take the form of either multiple orsingle quantum well configuration which is per se well known in the art.

The p-type upper cladding 13 overlying the active layer 12 may befabricated from any of the p-type Group III-V compound semiconductorsthat are generally defined as:Al_(x)Ga_(y)In_(1-x-y)Pwhere the subscripts x and y are both numerals that are equal to orgreater than zero and equal to or less than one, and the sum of x and yis equal to or greater than zero and equal to or less than one.Preferably, the aluminum proportion x of the upper cladding 13 is fromabout 0.15 to about 0.45. The p-type impurity (e.g. zinc) of the uppercladding 13 is not less than 5×10¹⁷ cm⁻³. As is well known, the bandgapof this upper cladding 13 is greater than that of the active layer 12.

The current spreading layer 14 on the upper cladding 13 is designed toserve the triple purpose of enhancing uniformity in the distribution ofthe forward current flowing through the light-generating semiconductorregion 2, assuring ohmic contact with the anode 3, and permittingunimpeded passage of the light therethrough for emission from the LED.The current spreading layer 14 can be made from any such p-type GroupIII-V compound semiconductor as GaP, Ga_(x)In_(1-x)P, orAl_(x)Ga_(1-x)As. The p-type impurity concentration of this currentspreading layer 14 is made higher than that of the upper cladding 13. Ap-type contact layer could be laid over the current spreading layer 14for better ohmic contact with the anode 3.

Arranged centrally on the top surface 15 of the semiconductor region 2in underlying relationship to part of the anode 3, the current blockinglayer 10 is made from an electrically insulating material in order topreclude concentrated current flow through the underlying central partof the semiconductor region.

The open-worked anode 3 as the first electrode covers the entire topsurface 15 of the semiconductor region 2 as well as the current blockinglayer 10 formed thereon, making ohmic contact with the current spreadinglayer 14. In practice the anode 3 may be a lamination of a chromium anda gold layer. As seen in a direction normal to the top surface 15 of thesemiconductor region 2, the anode 3 is meshed or latticed in shape inorder to permit emission of the light therethrough and to cause uniformflow of forward current through the entire semiconductor region. Atransparent material might be employed for the anode 3.

The ohmic contact regions 11 are made from a mixture of at least twometals including gallium and are pervious to the light generated by thelight-generating semiconductor region 2. FIG. 2 better reveals the arrayof discrete ohmic contact regions 4 embedded in the bottom surface 16 ofthe semiconductor region 2, or of its n-type lower cladding 11. It istherefore both ohmic contact regions 4 and lower cladding 11 that definethe bottom surface 16 of the semiconductor region 2. Made practicallysolely from a mixture or alloy of gallium and gold to a thickness ofapproximately 20 to 1000 angstroms, the ohmic contact regions 4 makeohmic contact with both lower cladding 11 and underlying reflectivelayer 5. The ohmic contact regions 4 would not make proper ohmic contactwith the neighboring layers if less than about 20 angstroms thick, andwould not be sufficiently pervious to light if more than about 1000angstroms thick.

Made from a mixture of gold and gallium, the ohmic contact regions 4will be less absorptive of light than the prior artgold-germanium-gallium alloy regions on the underside of thelight-generating semiconductor region of the LED according to JapaneseUnexamined Patent Publication No. 2002-217450, supra. Further, if madefrom an alloy of gold and gallium, the ohmic contact regions 4 are morepermeable to light than are the same prior art gold-germanium-galliumalloy regions. These prior art alloy regions contain light-blockinggermanium and are as thick as 2000 angstroms or more, blocking orabsorbing an inconveniently high proportion of the light impingingthereon. By contrast the ohmic contact regions 4 according to theinvention do not contain germanium and are as thin as about 20 to 1000angstroms, permitting the permeation of a much greater proportion oflight.

The reflective layer 5, covering the surfaces of the ohmic contactregions 4 and that of the n-type lower cladding 11 exposed therethrough,is higher in reflectivity than the ohmic contact regions 4. Part of thelight that has been radiated from the active layer 12 toward the bottomsurface 16 of the semiconductor region 2 is reflected by the surface ofthe reflective layer 5 that is exposed through the ohmic contact regions4, back toward the top surface 15 of the semiconductor region 2. Therest of the light that has been radiated toward the semiconductor regionbottom surface 16 is in part reflected by the surfaces of the ohmiccontact regions 4 and in part, after traversing these ohmic contactregions, reflected by the underlying surface portions of the reflectivelayer 5, both again back toward the semiconductor region top surface 15.

In this embodiment of the invention the total reflectivity of thegold-gallium ohmic contact regions 4 and the underlying parts of thereflective layer 5 is approximately 60 percent, which is twice as muchas that of the prior art gold-germanium-gallium alloy regions and theunderlying parts of the reflective layer.

The reflective layer 5 has the bonding metal layer 6 of gold formed onits complete underside. The other bonding metal layer 7, which also isof gold, is formed on the complete top surface of the electro-conductivesilicon baseplate 8. This baseplate is bonded to the underside of thereflective layer 5 as the two bonding metal layers 6 and 7 are joined toeach other under heat and pressure. Made from silicon doped withimpurifies, the baseplate 8 serves as a mechanical support of the LED,in addifion to as a heat radiator and current path. The baseplate 8 isdifferent from the substrate, not shown, that is used for growingthereon the constituent layers 11-14 of the light-generatingsemiconductor region 2, as will be better understood from the subsequentdisclosure of the method of manufacturing this LED 1.

The cathode 9 as the second electrode is formed on the entire bottomsurface of the baseplate 8. This cathode will be unnecessary, however,if a metal-made baseplate is employed in place of the silicon baseplate,as the metal-made baseplate will perform the function of a cathode aswell.

Method of Fabrication

The fabrication of the LED 1 shown in FIGS. 1 and 2 started with thepreparation of a gallium arsenide substrate, not shown. Thesemiconductor region 2 was formed on this GaAs substrate by successivelygrowing by metal organic chemical vapor deposition (MOCVD) the n-typelower cladding 11, active layer 12, p-type upper cladding 13, andcurrent spreading layer 14. Then the gallium arsenide substrate wasremoved from under the completed semiconductor region 2. FIG. 3 showsthe thus completed semiconductor region 2.

Then, for creation of the array of isolated ohmic contact regions 4,FIGS. 1 and 2, there were first formed on the entire bottom surface 16of the semiconductor region 2 a transition metal layer of chromium (Cr)and, thereon, a diffusible meal layer of gold, both by vacuumdeposition. Then an etchant-resist mask was laid over the diffusiblemeal layer and transition metal layer by known photolithography, andthese layers were selectively etched away through the etchant-resistmask thereby leaving an array of isolated regions of transition metallayer 17, FIG. 4, and of diffusible metal layer 18 on the now exposedbottom surface 16 of the semiconductor region 2. The transition metallayer 17 could be from about 10 to 500 angstroms thick, and thediffusible metal layer 18 from about 200 to 10,000 angstroms thick.

Speaking more broadly, the transition metal layer could be any of:

-   -   1. A layer of at least either of Ti, Ni, Sc, V, Mn, Fe, Co, Cu,        Zn, and Be in addition to Cr;    -   2. A lamination of an Au sublayer, Cr sublayer, and another Au        sublayer;    -   3. A lamination of a Cr sublayer, Ni sublayer, and Au sublayer;        and    -   4. A lamination of a Cr sublayer, AuSi sublayer, and Au        sublayer.

Again speaking broadly, the diffusible metal layer could be any of thefollowing in addition to the exemplified layer of gold only:

-   -   1. A lamination of an Au sublayer, Cr sublayer, and another Au        sublayer;    -   2. A lamination of a Cr sublayer, Ni sublayer, and Au sublayer;        and    -   3. A lamination of a Cr sublayer, AuSi sublayer, and Au        sublayer.

There is an alternative method of creating the array of isolated regionsof transition metal layer 17 and diffusible metal layer 18 as in FIG. 4.The bottom surface 16 of the semiconductor region 2 may first be coveredwith a mask having an array of windows formed therein. Then thetransition metal layer 17 and diffusible metal layer 18 may be formedone after the other by vacuum deposition on the mask as well as on thoseparts of the semiconductor region bottom surface 16 which are exposedthrough the windows in the mask. Then the mask may be removed togetherwith the overlying parts of the transition metal layer 17 and diffusiblemetal layer 18 thereby leaving an array of isolated regions of layers 17and 18 on the semiconductor region bottom surface 16 as in FIG. 4.

Then the FIG. 4 article was heated to a temperature (e.g. 300° C.) thatis lower than the eutectic temperature (345° C.) of gallium in then-type lower cladding 11 and gold in the diffusible metal regions 18 andat which gold (or some other diffusible metal in cases where such ametal is employed in lieu of gold) can be diffused into the lowercladding with the aid of the transition metal regions 17. The desiredohmic contact regions 4 of a gallium-and-gold mixture were thus createdas in FIG. 5 as the gold was diffused into the lower cladding 11 throughthe transition metal layer 17.

The heat treatment above may be effected at such a temperature, and forsuch a period of time, that the ohmic contact regions 4 may be formed toa thickness ranging from about 20 to about 1000 angstroms. Thetemperature in particular may be so determined as to create the ohmiccontact regions 4 that are unvarying in thickness and low in resistanceand that make good ohmic contact with the lower cladding 11.

Tests were conducted in order to ascertain the reflectivity of the Au—Gaohmic contact regions 4 according to the invention in comparison withthat of the noted prior art Au—Ge—Ga ohmic contact regions. The curve Ain the graph of FIG. 9 plots the total reflectivity of the Au—Ga ohmiccontact regions 4 and the underlying parts of the reflective layer 5according to the invention against the temperature of the heattreatment. The curve B in the same graph plots the total reflectivity ofthe prior art Au—Ge—Ga ohmic contact relations and the underlying partsof the reflective layer against the temperature of the heat treatmentfor creation of the ohmic contact regions. The reflectivities weremeasured for red light with a wavelength of 650 nanometers.

The reflectivity at 300° C. according to the invention is approximately30 percent, twice as high as that according to the prior art. It willalso be observed from this graph that the lower the temperature of theheat treatment, the higher is the reflectivity. But the contactresistance between the ohmic contact regions and the lower cladding 11grows inconveniently high if the temperature of the heat treatment istoo low. The temperature of the heat treatment should therefore be fromabout 250° to about 340°, preferably from about 290° to about 330° C.,in order to keep the contact resistance not more than 2×10⁻⁴ ohm-cm².

The transition metal regions 17, FIGS. 4 and 5, are effective both todecompose the AlGaInP of the lower cladding 11 into the individualelements, imparting greater mobility thereto, and to cleanse the surfaceof the lower cladding. These functions of the transition metal regions17 are conducive to gold diffusion into the lower cladding 11 at atemperature less than the eutectic point of gallium and gold, with theconsequent creation of the extremely thin ohmic contact regions 4 of amixture or alloy of these metals.

Then the transition metal regions 17 and diffusible metal regions 18were etched away, leaving the ohmic contact regions 4 which wereembedded in the lower cladding 11. FIG. 6 shows the resultingsemiconductor region 2 with the ohmic contact regions 4. Fabricated bythe above described method, the Au—Ga ohmic contact regions 4 accordingto the was far better in surface morphology than the prior art Au—Ge—Garegions. The bottom surface 16 of the semiconductor region 2, includingthe exposed surfaces of the ohmic contact regions 4, was thereforeflatter than the corresponding surface of the prior art.

Then, on this bottom surface 16 of the semiconductor region 2, aluminumwas vacuum deposited to a thickness of one to 10 micrometers, and thedeposit was heated with an infrared lamp, thereby completing thereflective layer 5 shown in FIG. 7. The electroconductive reflectivelayer 5 makes ohmic contact with the exposed surfaces of the ohmiccontact regions 4. Further, as the reflective layer 5 makes Schottkycontact with the exposed surface of the lower cladding 11, the forwardcurrent of the LED 1 does not flow from the lower cladding to thereflective layer. The reflective layer 5 was highly favorable inflatness thanks to the improved surface morphology of the ohmic contactregions 4.

Then, as shown also in FIG. 7, the bonding metal layer 6 was formed onthe surface of the reflective layer 5 by vacuum deposition of gold.

There was separately prepared the baseplate 8 of doped silicon which, ashas been stated, is to function as a mechanical support for the otherconstituent parts of the LED. The bonding metal layer 7 of gold wasformed on one of the opposite major surfaces of the baseplate 8 byvacuum deposition. This layer 7 was held under pressure against thebonding metal layer 6 on the underside of the reflective layer 5, andboth layers 6 and 7 were heated to a temperature not exceeding 300° C.thereby causing both layers to unite with each other by the mutualwelding of gold. The baseplate 8 was thus integrally joined to thereflective layer 5.

Then, referring back to FIG. 1, the current blocking layer 10 and anode3 were conventionally formed on the top surface 15 of the semiconductorregion 2. The cathode 9 was formed on the underside of the baseplate 8.Thus was completed the fabrication of the LED 1.

The advantages gained by this particular embodiment of the invention maybe recapitulated as follows:

-   -   1. The ohmic contact regions 4 and the underlying parts of the        reflective layer 5 are as high in total reflectivity as 60        percent thanks to the absence of light-absorbing germanium from        the ohmic contact regions and to their reduced thickness. A much        greater proportion than heretofore of the light that has been        radiated from the active layer 12 toward the reflective layer 5        is sent back toward the light-emitting surface 15 of the LED,        resulting in a significantly higher efficiency of light        production per unit of electric power consumed.    -   2. The ohmic contact regions 4 can be made larger than their        conventional counterparts for a given area of the bottom surface        16 of the light-generating semiconductor region 2 and for a        given optical output by reason of the improved total        reflectivity of the ohmic contact regions and the underlying        parts of the reflective layer 5. Such larger ohmic contact        regions lead to less forward resistance, less forward voltage        drop and power loss, and higher efficiency. The maximum        efficiency of the red light emitting diode 1 was 47 lumens per        watt at a current density of 40 amperes per square centimeter.    -   3. The ohmic contact regions 4 of gold and gallium are capable        of creation at a temperature less than their eutectic point by        thermal diffusion of gold from the diffusible metal regions 18        into the n-type lower cladding 11 via the transition metal        regions 17.    -   4. The electroconductive silicon baseplate 8 can be firmly        bonded to the reflective layer 5 by virtue of the improved        surface morphology of the ohmic contact regions 4.

Embodiment of FIG. 10

Another preferred form of LED 1 _(a) shown in FIG. 1 has an integralohmic contact region 4 _(a) covering the entire bottom surface 16 of thelower cladding 11. A relatively high efficiency is neverthelessobtainable because the total reflectivity of the ohmic contact region 4_(a) and reflective layer 5 is as high as 60 percent. As the ohmiccontact region 4 _(a) is larger than all the isolated ohmic contactregions 4 of FIGS. 1 and 2 combined, so much is reduced the resistanceto forward current flow, with a corresponding diminution of power loss.

Another feature of the alternative LED 1 _(a) resides in a metal-madebaseplate 8 _(a) which is affixed to the reflective layer 5 under heatand pressure in place of the silicon baseplate 8 of the previousembodiment. No dedicated cathode is provided as the baseplate 8 _(a)serves as both mechanical support and cathode.

The alternative LED 1 _(a) is akin to the first disclosed LED 1 in allthe other details of construction. The integrated ohmic contact regions4 a are created by the same method, and with the same composition and tothe same thickness, as their FIGS. 1 and 2 counterpart 4, so that theLED 1 _(a) offers substantially the same advantages as the LED 1.

Possible Modifications

Notwithstanding the foregoing detailed disclosure it is not desired thatthe present invention be limited by the exact showings of the drawingsor the description thereof. The following is a brief list of possiblemodifications, alterations or adaptations of the illustrated embodimentsof the invention which are all believed to fall within the purview ofthe claims annexed hereto:

-   -   1. The silicon baseplate 8, FIG. 1, and metal-made baseplate 8        a, FIG. 10, may both be omitted if the light-generating        semiconductor region is sufficiently sturdy and self-supporting.        The electroconductive reflective layer 5 will then serve also as        cathode, so that the dedicated cathode 9 may also be omitted        from the FIG. 1 construction.    -   2. The ohmic contact regions 4 need not be rectangular as in        FIG. 2 but may be circular or otherwise in shape. They need not        be separated into discrete units, either, but may be latticed or        otherwise joined to one another, besides being wholly combined        into a single, closed layer as indicated at 4 _(a) in FIG. 10.    -   3. An n-type contact layer of AlGaInP and/or n-type buffer layer        of AlGaInP could be interposed between the n-type lower cladding        11 and the reflective layer, and the ohmic contact regions 4 or        region 4 _(a) could be formed in contact therewith instead of        with the lower cladding.    -   4. The ohmic contact regions 4 or region 4 _(a) may be made from        Au—Ge—Ga alloy or some such material other than Au—Ga alloy or        mixture, provided that the resulting ohmic contact region or        regions are permeable to the light generated by the LED. The        total reflectivity of such ohmic contact region or regions and        the reflective layer will be raised to a satisfactory level if        the thickness of the ohmic contact region or regions are limited        to the range of from about 20 to about 1000 angstroms.    -   5. The diffusible metal regions 18, FIGS. 4 and 5, could be of a        gold-based alloy or Ga-based alloy.    -   6. The reflective layer 5 of the LED 1, FIG. 1, could be        provided only under the ohmic contact regions 4 or under the        exposed surface portions of the lower cladding 11.    -   7. The active layer 12 can be made from any such III-V compound        semiconductor as Al_(x)Ga_(y)In_(1-x-y)As or        Al_(x)Ga_(y)In_(1-x-y)N. Also, the p-type upper cladding 13 can        be made from any such III-V compound semiconductor as        Al_(x)Ga_(y)In_(1-x-y)As or Al_(x)Ga_(y)In_(1-x-y)N.

1. A light-emitting semiconductor device of improved efficiency,comprising: (a) a light-generating semiconductor region having a firstmajor surface from which light is emitted and a second major surfacewhich is opposite to the first major surface, the light-generatingsemiconductor region comprising a plurality of compound semiconductorlayers including a gallium-containing compound semiconductor layer whichis exposed at the second major surface of the semiconductor region; (b)an electrode on the first major surface of the semiconductor region; (c)an ohmic contact region held in ohmic contact with at least part of thesecond major surface of the light-generating semiconductor region, theohmic contact region being made from a mixture of at least two metalsincluding gallium; and (d) a reflective layer of electrically conductingmaterial held against at least either of the ohmic contact region andthat part, if any, of the gallium-containing compound semiconductorlayer of the light-generating semiconductor region which is exposed atthe second major surface of the semiconductor region through the ohmiccontact region, for reflecting the light from the semiconductor regionback toward the semiconductor region for emission from the first majorsurface thereof.
 2. A light-emitting semiconductor device as defined inclaim 1, wherein the ohmic contact region is of a mixture of gallium andgold.
 3. A light-emitting semiconductor device as defined in claim 1,wherein the ohmic contact region is from abut 20 to about 1000 angstromsin thickness.
 4. A light-emitting semiconductor device as defined inclaim 1, wherein the gallium-containing compound semiconductor layer ofthe light-generating semiconductor region is made from one of thefollowing three compound semiconductors and a conductivity-typedeterminant: (a) a first compound semiconductor that is generallyexpressed as Al_(x)Ga_(y)In_(1-x-y)P where the subscript x is a numeralthat is equal to or greater than zero and less than one; the subscript yis a numeral that is greater than zero and equal to or less than one;and the sum of x and y is greater than zero and equal to or less thanone; (b) a second compound semiconductor that is generally expressed asAl_(x)Ga_(y)In_(1-x-y)As where the subscript x is a numeral that isequal to or greater than zero and less than one; the subscript y is anumeral that is greater than zero and equal to or less than one; and thesum of x and y is greater than zero and equal to or less than one; and(c) a third compound semiconductor that is generally expressed asAl_(x)Ga_(y)In_(1-x-y)N where the subscript x is a numeral that is equalto or greater than zero and less than one; the subscript y is a numeralthat is greater than zero and equal to or less than one; and the sum ofx and y is greater than zero and equal to or less than one.
 5. Alight-emitting semiconductor device as defined in claim 1, wherein thereflective layer is made from a metal that is more reflective than themetals of the ohmic contact region.
 6. A light-emitting semiconductordevice as defined in claim 5, wherein the reflective layer is ofaluminum.
 7. A light-emitting semiconductor device as defined in claim1, further comprising an electroconductive baseplate attached to thereflective layer.
 8. A light-emitting semiconductor device as defined inclaim 7, wherein the baseplate is of doped silicon, and wherein a secondelectrode is formed on the baseplate.
 9. A light-emitting semiconductordevice as defined in claim 1, wherein the ohmic contact region isopen-worked to expose part of the second major surface of thelight-generating semiconductor region, and wherein the reflective layercovers both the ohmic contact region and the exposed part of the secondmajor surface of the semiconductor region.
 10. A light-emittingsemiconductor device as defined in claim 1, wherein thegallium-containing compound semiconductor layer of the light-generatingsemiconductor region exposed at the second major surface thereof is alower cladding, and wherein the semiconductor region further comprises:(a) an active layer of gallium-containing compound semiconductormaterial on the lower cladding; and (b) an upper cladding ofgallium-containing compound semiconductor material on the active layer,the upper cladding being opposite in conductivity type to the lowercladding.
 11. A method of making a light-emitting semiconductor deviceof improved efficiency, which comprises: (a) providing alight-generating semiconductor region having a first major surface fromwhich light is emitted and a second major surface which is opposite tothe first major surface, the light-generating semiconductor regioncomprising a plurality of compound semiconductor layers including agallium-containing compound semiconductor layer which is exposed at thesecond major surface of the semiconductor region; (b) creating atransition metal layer containing a transition metal on at least part ofthe second major surface of the light-generating semiconductor region;(c) creating a diffusible metal layer on the first metal layer, thediffusible metal layer containing a metal that can be thermally diffusedinto the gallium-containing compound semiconductor layer of thelight-generating semiconductor region through the transition meal layer;(d) creating an ohmic contact region in the gallium-containing compoundsemiconductor layer of the light-generating semiconductor region bycausing thermal diffusion of the diffusible metal from the diffusiblemetal layer into the gallium-containing compound semiconductor layerthrough the transition metal layer at a temperature less than theeutectic point of elements constituting the gallium-containing compoundsemiconductor layer and the diffusible metal; (e) removing thetransition metal layer and the diffusible metal layer from thelight-generating semiconductor region; and (f) creating a reflectivelayer of electrically conducting material on at least either of theohmic contact region and that part, if any, of the gallium-containingcompound semiconductor layer of the light-generating semiconductorregion which is exposed at the second major surface of the semiconductorregion through the ohmic contact region.
 12. A method of making alight-emitting semiconductor device as defined in claim 11, wherein thetransition metal layer together with the diffusible metal layer thereonis formed in discrete regions on the second major surface of thelight-generating semiconductor region, covering parts, and uncoverig therest, of the second major surface, so that ohmic contact regions arecreated only in those parts of the gallium-containing compoundsemiconductor layer of the light-generating semiconductor region whichhave been covered by the discrete regions of the transition metal layerand the diffusible metal layer.
 13. A method of making a light-emittingsemiconductor device as defined in claim 12, wherein the reflectivelayer is created on the complete second major surface of thelight-generating semiconductor region.
 14. A method of making alight-emitting semiconductor device as defined in claim 11, wherein thegallium-containing compound semiconductor layer of the light-generatingsemiconductor region is made from one of the following three compoundsemiconductors and a conductivity-type determinant: (a) a first compoundsemiconductor that is generally expressed as Al_(x)Ga_(y)In_(1-x-y)Pwhere the subscript x is a numeral that is equal to or greater than zeroand less than one; the subscript y is a numeral that is greater thanzero and equal to or less than one; and the sum of x and y is greaterthan zero and equal to or less than one; (b) a second compoundsemiconductor that is generally expressed as Al_(x)Ga_(y)In_(1-x-y)Aswhere the subscript x is a numeral that is equal to or greater than zeroand less than one; the subscript y is a numeral that is greater thanzero and equal to or less than one; and the sum of x and y is greaterthan zero and equal to or less than one; and (c) a third compoundsemiconductor that is generally expressed as Al_(x)Ga_(y)In_(1-x-y)Nwhere the subscript x is a numeral that is equal to or greater than zeroand less than one; the subscript y is a numeral that is greater thanzero and equal to or less than one; and the sum of x and y is greaterthan zero and equal to or less than one.
 15. A method of making alight-emitting semiconductor device as defined in claim 11, wherein thegallium-containing compound semiconductor layer of the light-generatingsemiconductor region is made from a conductivity-type determinant and acompound semiconductor that is generally expressed asAl_(x)Ga_(y)In_(1-x-y)P where the subscript x is a numeral that is equalto or greater than 0.4 and less than 1.0; the subscript y is a numeralthat is greater than zero and equal to or less than one; and the sum ofx and y is greater than zero and equal to or less than one.
 16. A methodof making a light-emitting semiconductor device as defined in claim 15,wherein the gallium-containing compound semiconductor layer of thelight-generating semiconductor region contains the conductivity-typedeterminant with a concentration of not less than 10¹⁸ cm⁻³.
 17. Amethod of making a light-emitting semiconductor device as defined inclaim 11, wherein the transition metal layer is selected from among: (a)a layer of at least either of Cr, Ti, Ni, Sc, V, Mn, Fe, Co, Cu, Zn, andBe; (b) a lamination of an Au sublayer, Cr sublayer, and another Ausublayer; (c) a lamination of a Cr sublayer, Ni sublayer, and Ausublayer; and (d) a lamination of a Cr sublayer, AuSi sublayer, and Ausublayer.
 18. A method of making a light-emitting semiconductor deviceas defined in claim 11, wherein the diffusible metal layer is selectedfrom among: (a) a gold layer: (b) a lamination of an Au sublayer, Crsublayer, and another Au sublayer; (c) a lamination of a Cr sublayer, Nisublayer, and Au sublayer; and (d) a lamination of a Cr sublayer, AuSisublayer, and Au sublayer.
 19. A method of making a light-emittingsemiconductor device as defined in claim 11, wherein the diffusiblemetal is gold, which is so diffused into the gallium-containing compoundsemiconductor layer of the light-generating semiconductor region thatthe ohmic contact region created is of an alloy of gallium and gold. 20.A method of making a light-emitting semiconductor device as defined inclaim 11, wherein the ohmic contact region is from about 20 to about1000 angstroms thick.
 21. A method of making a light-emittingsemiconductor device as defined in claim 11, wherein the reflectivelayer is made from a metal selected to possess a higher reflectivitythan does the ohmic contact region.
 22. A method of making alight-emitting semiconductor device as defined in claim 21, wherein thereflective layer is made from aluminum.
 23. A method of making alight-emitting semiconductor device as defined in claim 11, whichfurther comprises joining an electroconductive baseplate to thereflective layer.
 24. A method of making a light-emitting semiconductordevice as defined in claim 23, wherein the electroconductive baseplateis of doped silicon, and wherein the method further comprises joining anelectrode to the baseplate.